Percale Bedding System

ABSTRACT

Percale weave sheeting has warp yarn and weft yarn. The percale weave sheeting has two surfaces. Both surfaces exhibit color consistency. The warp yarn and the weft yarn are a cross weave of cotton and polyester.

RELATED APPLICATIONS

The present application is a continuation-in-part of pending U.S.application Ser. No. 15/288,263 filed Oct. 7, 2016, which is acontinuation-in-part of pending U.S. application Ser. No. 14/828,868filed Aug. 18, 2015, which is a continuation-in-part of abandoned U.S.application Ser. No. 14/698,466 filed Apr. 28, 2015, which is acontinuation-in-part of abandoned U.S. application Ser. No. 14/668,124filed Mar. 25, 2015, the subject matter of which applications isincorporated herein by reference and the priority of which is herebyclaimed.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to a percale bedding system and moreparticularly pertains to bedding fabricated of a percale fabriccharacterized by anti-wrinkle capabilities, increased softness andincreased durability/long life, and decreased cost.

Description of the Prior Art

The use of bedding fabric of known designs and configurations is knownin the prior art. More specifically, bedding fabric of known designs andconfigurations previously devised and utilized for the purpose offabricating bedding are known to consist basically of familiar,expected, and obvious structural configurations, notwithstanding themyriad of designs encompassed by the crowded prior art which has beendeveloped for the fulfillment of countless objectives and requirements.

While the prior art fabrics fulfill their respective, particularobjectives and requirements, they do not describe a percale beddingsystem that is characterized by anti-wrinkle capabilities, increasedsoftness and increased durability/long life, and decreased cost.

In this respect, the percale bedding system according to the presentinvention substantially departs from the conventional concepts anddesigns of the prior art, and in doing so provides a fabric weaveprimarily developed for the purpose of fabricating bedding of a percalefabric characterized by anti-wrinkle capabilities, increased softnessand increased durability/long life, and decreased cost.

Therefore, it can be appreciated that there exists a continuing need fora new and improved percale bedding system which can be used forfabricating bedding of a percale fabric characterized by anti-wrinklecapabilities, increased softness and increased durability/long life, anddecreased cost. In this regard, the present invention substantiallyfulfills this need.

SUMMARY OF THE INVENTION

In view of the foregoing disadvantages inherent in the types of beddingfabric of known designs and configurations now present in the prior art,the present invention provides an improved percale bedding system. Assuch, the general purpose of the present invention, which will bedescribed subsequently in greater detail, is to provide a new andimproved percale bedding system and method which has all the advantagesof the prior art and none of the disadvantages.

To attain this, the present invention broadly is fabric fabricated ofpercale weave sheeting. The sheeting has warp yarn and weft yarn. Thewarp yarn and the weft yarn are a cross weave of cotton and polyester.

There has thus been outlined, rather broadly, the more importantfeatures of the invention in order that the detailed description thereofthat follows may be better understood and in order that the presentcontribution to the art maybe better appreciated. There are, of course,additional features of the invention that will be described hereinafterand which will form the subject matter of the claims attached.

In this respect, before explaining at least one embodiment of theinvention in detail, it is to be understood that the invention is notlimited in its application to the details of construction and to thearrangements of the components set forth in the following description orillustrated in the drawings. The invention is capable of otherembodiments and of being practiced and carried out in various ways.Also, it is to be understood that the phraseology and terminologyemployed herein are for the purpose of descriptions and should not beregarded as limiting.

As such, those skilled in the art will appreciate that the conception,upon which this disclosure is based, may readily be utilized as a basisfor the designing of other structures, methods and systems for carryingout the several purposes of the present invention. It is important,therefore, that the claims be regarded as including such equivalentconstructions insofar as they do not depart from the spirit and scope ofthe present invention.

It is therefore an object of the present invention to provide a new andimproved percale bedding system which has all of the advantages of theprior art bedding fabric of known designs and configurations and none ofthe disadvantages.

It is another object of the present invention to provide a new andimproved percale bedding system which may be easily and efficientlymanufactured and marketed.

It is a further object of the present invention to provide a new andimproved percale bedding system which is of durable and reliableconstructions.

An even further object of the present invention is to provide a new andimproved percale bedding system which is susceptible of a low cost ofmanufacture with regard to both materials and labor, and whichaccordingly is then susceptible of low prices of sale to the consumingpublic, thereby making such percale bedding system economicallyavailable to the buying public.

Lastly, it is an object of the present invention to provide a new andimproved bedding system fabricated of a percale fabric characterized byanti-wrinkle capabilities, increased softness and increaseddurability/long life, and decreased cost.

These together with other objects of the invention, along with thevarious features of novelty which characterize the invention, arepointed out with particularity in the claims annexed to and forming apart of this disclosure. For a better understanding of the invention,its operating advantages and the specific objects attained by its uses,reference should be had to the accompanying drawings and descriptivematter in which there is illustrated preferred embodiments of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood and objects other than those setforth above will become apparent when consideration is given to thefollowing detailed description thereof. Such description makes referenceto the annexed drawings wherein:

FIG. 1 is a perspective illustration of a percale bedding systemfabricated in accordance with the principles of the present invention.

FIG. 2 is a front elevational view of the top sheet and pillow cases ofFIG. 1.

FIG. 3 is front elevational view of the fitted sheet of FIG. 1.

FIG. 4 is an enlarged front elevational view of the fabric of thebedding of the prior Figures.

FIG. 5 is a graph charting 15 denier to 240 denier polyester filamentyarn against 140 thread count to 1200 thread count threads per inch ofcotton rich grid.

FIG. 6 is a graph charting 15 denier to 240 denier polyester filamentyarn against 140 thread count to 1200 thread count threads per inch andmeasuring tensile strength.

FIG. 7 is a graph charting 15 denier to 240 denier polyester filamentyarn against 140 thread count to 1200 thread count threads per inch andmeasuring fabric increased durability grid.

The same reference numerals refer to the same parts throughout thevarious Figures.

DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference now to the drawings, and in particular to FIG. 1 thereof,the preferred embodiment of the new and improved percale bedding systemembodying the principles and concepts of the present invention andgenerally designated by the reference numeral 10 will be described.

The present invention, the percale bedding system 10 is comprised of aplurality of components. Such components in their broadest contextinclude percale weave sheeting having warp yarn and weft yarn, the warpyarn and the weft yarn being a cross weave of cotton and polyester.

In the preferred embodiment, bedding 10 is characterized by anti-wrinklecapabilities, increased softness and increased durability/long life, anddecreased cost. The bedding is fabricated of percale weave sheeting. Thepercale weave sheeting has two surfaces wherein both surfaces exhibitcolor consistency. The bedding includes one, two, or four pillow cases12, a top sheet 14, and a fitted sheet 16.

The percale weave sheeting has cotton warp yarn 18 with a denier of 10 Dto 240 D with 14 to 216 filament thread count. The cotton warp yarn hasa thread count of 30 s to 60 s. The cotton warp yarn is a rich chiefvalue cotton, CVC, with a 51 percent minimum of cotton and a 49 percentmaximum of polyester/filament yarn, or polyester spun yarn, or polyestercotton spun yarn.

The percale weave sheeting has polyester weft yarn 20 with a denier of10 D to 240 D. The polyester weft yarn is polyester filament, lowintermingle. The polyester weft yarn is 14 filament to 216 filamentthread count thereby providing improved crispness.

The percale weave sheeting has 130 to 2000 threads per square inch. Thepercale weave sheeting has a weight of 80 to 250 grams per square inchthereby exhibiting high tensile strength.

The cotton warp yarn and the polyester weft yarn in each surface are inacross weave, 1/1, 1 over 1 and under. The warp and weft, which arepreferably cotton and polyester, may be interchanged to polyester warpand cotton weft whereby both surfaces comprise a proportion of cottonand a proportion of polyester, the proportion of cotton being greaterthan the proportion of polyester.

In alternate embodiments, the fabric is formed as a pillowcase, a topsheet, or a fitted sheet. In another alternate embodiment, the beddingincludes pillowcases, a top sheet, and a fitted sheet.

In a further alternate embodiment, the cross weave is 1/1, 1 over and 1under. In another embodiment, the cross weave is 1 over and 2 under. Instill another embodiment, the cross weave is ¼, 1 over and 4 under.

The present invention is percale sheeting manufactured into fineproducts including luxury percale bed sheets, fitted sheets and pillowcases. Such products are characterized by a percale weave construction1/1, 1 up 1 down, of a high thread count of at least about 130 threadsper square inch to 2000 threads per square inch thereby exhibiting lowpilling. Prior art percale sheets were either from 100 percent cotton orcotton with polyester filament yarn/polyester or spun yarn/polyester orcotton spun yarn. The sheeting of the present invention is chief valuecotton, CVC, that is predominant cotton with the cotton comprising aminimum of 51 percent over polyester filament yarn/polyester spunyarn/polyester cotton spun yarn which will be a maximum 49 percent. Thecotton yarn count can vary from 30 s to 60 s thread count and polyesterfilament yarn/polyester or spun yarn/polyester cotton spun yarn whichcan vary from 10 D up to 240 D with 14 filament to 216 filament threadcount.

The polyester fibers were included in the prior art cotton percalebecause of the cost of the polyester yarn which was much cheaper thanthe cotton yarn. Hence, a product with polyester will be cheaper for theconsumer, value for money in the hands of the consumer.

The polyester-cotton fabric of the present invention gives wrinkleresistance. Moreover, polyester yarn is known for its increaseddurability adding to the tensile strength, increased durability,dimensional stability, wear and tear performance of the fabric of thepresent invention thereby making it more attractive for the consumer.

Sheeting fabrics suitable for use in the present invention are of aplain weave construction with a thread count of at least about 130threads per inch up to 2000 threads per inch. Cotton yarn count from 30s to 60 s with 10 denier to 240 denier with 14 filaments to 216filament, and typically have a weight range of about 80 grams per squaremeter to 250 grams per square meter thereby exhibiting high tensilestrength. They are generally of a substantially balanced construction.The percale weave is a closed construction and is balanced with warp andweft.

The sheeting fabric in accordance with the present invention comprises awoven percale sheeting fabric having a uniform woven fabric constructionof at least 130 thread count per inch up to 1200 threads per inchthroughout both the sheet areas and the heavier areas. The core spunyarns have a yarn count of about 30 s to 60 s in cotton and 10 D D to240 D of filament polyester/polyester spun yarn/polyester cotton spunyarn.

Percale sheeting fabric can be formed of a single common color, ordifferent colors, or of multiple colors by incorporating into the print,in addition to the oxidizing agent, suitable disperse dyestuffs whichsublime into the polyester core component. Polyester dyed is in dispersedyeing and cotton in reactive dyeing to match both components of fabricand the print will be in pigment dyes.

Cotton yarn will be from 30 s to 60 s yarn count made from eithercarded/combed/compact or Egyptian/pima/supima cotton. Percale fabric iswoven with warp cotton yarn 100 percent cotton/Egyptiancotton/pima/supima cotton and weft polyester filament yarn/polyesterspun yarn/polyester cotton spun yarn. In the alternative, it can beeither way with warp polyester filament yarn/polyester spunyarn/polyester cotton spun yarn and weft cotton yarn 100 percentcotton/Egyptian cotton/pima/supima cotton.

In addition polyester filament yarn, polyester spun yarn and polyestercotton spun yarn are added. The polyester filament yarn may also be CVC.

FIG. 5 is a graph charting 15 denier to 240 denier polyester filamentyarn against 140 thread count to 1200 thread count threads per inch ofcotton rich grid. This graph demonstrates that the sweet spot is 60percent cotton and is based on the test method AATCC 20 and 20A.

FIG. 6 is a graph charting 15 denier to 240 denier polyester filamentyarn against 140 thread count to 1200 thread count threads per inch andmeasuring tensile strength. This graph demonstrates that the tensilestrength sweet spot is 40 lbs by 40 lbs for both weft and warp as perASTM 5034 test method.

FIG. 7 is a graph charting 15 denier to 240 denier polyester filamentyarn against 140 thread count to 1200 thread count threads per inch andmeasuring fabric pilling grid. This graph demonstrates that the sweetspot in this test is grade 4.0 as per ASTM D4970 (100 Movement).

Note is taken of a comparison between the CVC bedding of the presentinvention and conventional satin CVC bedding.

a) The cotton content is more in percale weave than in satin weave, asin satin weave it is 4/1. The present invention has cotton only on thetop surface and the bottom is 100 percent polyester, where in percale itis 1/1 weave so the cotton portion is there on both surfaces so percalebedding is better.

b) The tensile strength is more in percale versus satin.

c) As both surfaces are the same in the present invention, the colorconsistency will be much higher and even in percale as compared tosatin.

d) There is also more crispness in the present invention since cotton ispresent on both sides in percale vs. satin.

e) Pilling is less and washing is better in percale versus satin as bothsurfaces are the same.

As to the manner of usage. and operation of the present invention, thesame should be apparent from the above description. Accordingly, nofurther discussion relating to the manner of usage and operation will beprovided.

With respect to the above description then, it is to be realized thatthe optimum dimensional relationships for the parts of the invention, toinclude variations in size, materials, shape, form, function and mannerof operation, assembly and use, are deemed readily apparent and obviousto one skilled in the art, and all equivalent relationships to thoseillustrated in the drawings and described in the specification areintended to be encompassed by the present invention.

Therefore, the foregoing is considered as illustrative only, of theprinciples of the invention. Further, since numerous modifications andchanges will readily occur to those skilled in the art, it is notdesired to limit the invention to the exact construction and operationshown and described, and accordingly, all suitable Modifications andequivalents may be resorted to, falling within the scope of theinvention.

What is claimed as being new and desired to be protected by LettersPatent of the United States is as follows:
 1. Fabric fabricated ofpercale weave sheeting, the percale weave sheeting having two surfaceswherein both surfaces-exhibit color consistency, the percale weavesheeting having warp yarn and weft yarn, the warp yarn and the weft yarnbeing a cross weave of cotton and polyester.
 2. The fabric as set forthin claim 1 wherein the percale weave sheeting is formed as a pillowcase.3. The fabric as set forth in claim 1 wherein the percale weave sheetingis formed as a top sheet.
 4. The fabric as set forth in claim 1 whereinthe percale weave sheeting is formed as a fitted sheet.
 5. The fabric asset forth in claim 1 wherein the percale weave sheeting is formed aspillowcases, a top sheet, and a fitted sheet.
 6. The fabric as set forthin claim 1 wherein the warp yarn is cotton, 10 D D to 240 D denier and30 s to 60 s thread count.
 7. The fabric as set forth in claim 6 whereinthe cotton is chief value cotton with a minimum of 51 percent cotton and49 percent chosen from polyester/filament yarn and polyester spun yarnand cotton spun yarn.
 8. The fabric as set forth in claim 1 wherein theweft yarn is polyester filament, low intermingle, 10 D D to 240 D denierand 14 filament to 36 filament thread count.
 9. The fabric as set forthin claim 1 wherein the weft yarn is polyester filament, low intermingle,10 D D to 240 D denier and 36 filament to 72 filament thread count. 10.The fabric as set forth in claim 1 wherein the weft yarn is polyesterfilament, low intermingle, 10 D D to 240 D denier and 72 filament to 108filament thread count.
 11. The fabric as set forth in claim 1 whereinthe warp yarn is cotton filament, with a yarn count of 30 to 60 s, and15 D to 240 D denier, and 14 to 216 filament, and wherein the weft yarnis polyester filament, low intermingled, 10 D D to 240 D denier and 14to 216 filament thereby providing improved crispness.
 12. The fabric asset forth in claim 1 wherein the cross weave is 1/1, 1 over and 1 under,whereby both surfaces comprise a proportion of cotton and a proportionof polyester, the proportion of cotton being greater than the proportionof polyester.
 13. The fabric as set forth in claim 1 wherein the crossweave is ½, 1 over and 2 under.
 14. The fabric as set forth in claim 1wherein the cross weave is ¼, 1 over and 4 under.
 15. The fabric as setforth in claim 1 wherein with the sheeting has a high thread count offrom 130 threads per inch to 00 threads per inch.
 16. The fabric as setforth in claim 1 wherein with the sheeting has a high thread count offrom 300 threads per inch to 600 threads per inch.
 17. The fabric as setforth in claim 1 wherein with the sheeting has a high thread count offrom 600 threads per inch to 800 threads per inch.
 18. The fabric as setforth in claim 1 wherein with the sheeting has a high thread count offrom 800 to 2000 threads per inch thereby exhibiting low pilling. 19.The fabric as set forth in claim 1 wherein the sheeting has a weightrange of 80 to 250 grams per square meter thereby exhibiting hightensile strength.